Cushioning device for large animals

ABSTRACT

The present invention relates to a cushion device for supporting a large animal such as a cow, a horse, a buffalo, a sheep, a goat, a pig and so forth. The cushioning device includes a top and bottom surface interconnected by a ‘drop stitch’ structure and a chamber. Contained within the chamber of the cushioning device is a filling material. The filling material includes a gaseous compound, a liquid or a mixture of a gaseous compound and a liquid. Additionally, the present invention also relates to the methods of transporting and installing the cushioning device. The device is shipped to the installation site absent the filling material. During installation a controlled mixture of dual phase fluids such as water and inert gas are disposed into the cushioning device, creating a gelatinous and gaseous filling material.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser. No.14/784,740, filed Oct. 15, 2015, now U.S. Pat. No. 10,136,614, issuedNov. 27, 2018, which is a national stage application under 35 U.S.C. §371 of International Application No. PCT/CA2014/050377, filed Apr. 15,2014, which in turn claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Ser. No. 61/812,012, filed Apr. 15, 2013, the contents ofeach of which are hereby incorporated by reference into the presentdisclosure.

FIELD OF INVENTION

The present invention relates to cushioning devices, specifically thepresent invention relates to a drop stitch fabric to form a mattress forproviding comfort to large animals. The present invention relates alsoto the transportation, installation and automatic control of thecushioning device at a desired pressure.

BACKGROUND OF INVENTION

Prior animal cushioning devices comprised of either a plurality ofcombined fabric chamber packed with comminuted rubber for example, U.S.Pat. No. 5,653,195 or utilizing a gelatinous material again housedwithin a plurality of chambers forming a mattress (WO2011/054091). Whilesuch mattresses do provide cushioning, the uneven surface generated byplurality of chambers fosters hygiene issues amongst the livestock asthese mattresses can be challenging to clean. Furthermore, theresiliency of the cushioning with the age of the mattress does begin totaper off, thus limiting the longevity of the mattress.

Another form of prior art is the inflatable kayak type boat U.S. Pat.No. 7,861,662 which utilizes the drop stitch structure to form a singlefloatation chamber. However the kayak of this prior art is solelypressurized with air, and not designed to resist the weight and forcesimparted by large animals, as this term is defined below.

Another form of prior art is the inflatable cushioning device withmanifold system U.S. Pat. No. 6,826,795 which uses a manifold system forproviding separately adjustable pressure zones within a singlecushioning device for human patients. Nevertheless, this prior art isdesigned for use with a single human patient and not designed towithstand the weight and forces imparted by large animals.

What is needed is a cushioning device that is capable of absorbing andwithstanding the dynamic and static forces imposed by large animals, allthe while maintaining or exceeding the level of comfort posed byexisting products. What is also needed is a cushioning device thatmaintains resiliency with age, thus increasing the longevity of thedevice. What is also needed is to utilize a manifold system to enablecustomizing the firmness and softness of a plurality of cushioningdevices for one animal up to several animals.

SUMMARY OF THE INVENTION

One object of the present invention is to provide a cushioning devicedesigned from a flat chamber, which may be a single flat chamber,capable of withstanding the forces imposed by large animals.

In one embodiment, the invention relates to a cushioning device. Thecushioning device, in one embodiment, includes a drop stitch structureand a chamber configured for receiving an amount of a filling material.

In one embodiment of the present invention, the cushioning devicefurther includes: (a) a top wall and (b) a bottom wall, the top andbottom surfaces being connected by the drop stitch structure.

In another embodiment of the cushioning device of the present invention,the filling material includes a gaseous compound.

In another embodiment of the cushioning device of the present invention,the filling material is a mixture of a gaseous compound and a liquid.

In another embodiment of the cushioning device of the present invention,the liquid is a gelatinous material based on a super absorbent polymer.

In another embodiment of the cushioning device of the present invention,the mixture comprises about 1-20% v/v % gaseous compound and about80-99% v/v % gelatinous material.

In another embodiment of the cushioning device of the present invention,the gaseous compound includes air, nitrogen, argon, or a combinationthereof.

In another embodiment of the cushioning device of the present invention,the amount of filling material within the chamber is sufficient to exerta positive pressure upon the chamber sufficiently beyond atmosphericpressure when there is no large animal on said cushioning device.

In another embodiment of the cushioning device of the present invention,the pressure within the chamber ranges between about 0.1 PSI to about 12PSI.

In another embodiment of the cushioning device of the present invention,the pressure within the chamber ranges between about 2.1 PSI to about 14PSI.

In another embodiment of the cushioning device of the present invention,the cushioning device includes at least one valve having means of fluidcommunication with a site exterior to the chamber.

In another embodiment of the cushioning device of the present invention,the means for communication with the site exterior to the chamberincludes a check valve or a valve having a septum disposed within.

In another embodiment of the cushioning device of the present invention,the cushioning device further includes at least one port connecting thechamber with an exterior of the cushioning device, and a cap for sealingthe at least one port, the cap comprising (i) a main body, (ii) aconnector extending from the main body, the connector designed forinterfacing with the port of the cushioning device, and (iii) a septumdisposed in the cap, the septum configured for receiving an inflationneedle there through and into the chamber of the cushioning device.

In another embodiment of the cushioning device of the present invention,the drop-stitch structure comprises two opposing base layers connectedby a plurality of threads, and wherein the two opposing layers directlyline the chamber of the cushioning device.

In another embodiment of the cushioning device of the present invention,the top and bottom walls include a fabric layer having a scrim.

In another embodiment of the cushioning device of the present invention,the cushioning device further includes an abrasion resistant materialadjacent to either or both the top and bottom walls.

In another embodiment of the cushioning device of the present invention,the cushioning device is in communication with a filling materialreservoir.

In another embodiment of the cushioning device of the present invention,the cushioning device further includes a filling material reservoir, anintake valve and an exhaust valve, at least the intake vale being incommunication with the filling material reservoir, the intake valvehaving an intake check valve configured for allowing filling material toflow into the cushioning device, while preventing the filling materialfrom flowing out of the cushioning device, and the exhaust valve havingan exhaust check valve configured for allowing filling material to flowout of the cushioning device, while preventing filling material fromflowing back into the cushioning device.

In another embodiment of the cushioning device of the present invention,the cushioning device is a large animal cushioning device.

In another embodiment of the cushioning device of the present invention,the large animal includes a cow, a horse, a buffalo a goat and a pig.

In another embodiment of the cushioning device of the present invention,the cushioning device when filled with the filling material is capableof withstanding an animal weighing more than about 400 Kg.

In another embodiment of the cushioning device of the present invention,the cushioning device when filled with the filling material is capableof withstanding an animal weighing between about 400 Kg and about 1,200Kg.

In one embodiment, the present invention provides a system including (a)at least one cushioning device according to any of the previousembodiments, and (b) a filling material reservoir in connection with theat least one cushioning device.

In one embodiment of the system of the present invention, each of the atleast one cushioning device includes at least one intake valve, at leastone exhaust valve, at least the intake vale being in communication withthe filling material reservoir, the at least one intake valve having anintake check valve configured for allowing filling material to flow intothe cushioning device, while preventing the filling material fromflowing out of the cushioning device, and the at least one exhaust valvehaving an exhaust check valve configured for allowing filling materialto flow out of the cushioning device, while preventing filling materialfrom flowing back into the cushioning device.

In another embodiment of the system of the present invention, the systemis maintained at a desired pressure.

In another embodiment of the system of the present invention, thecushioning device is a large animal cushioning device.

In another embodiment of the system of the present invention, the largeanimal includes a cow, a horse, a buffalo a goat and a pig.

In another embodiment of the system of the present invention, thecushioning device when filled with the filling material is capable ofwithstanding an animal weighing more than about 400 Kg.

In yet another embodiment of the system of the present invention, thecushioning device when filled with the filling material is capable ofwithstanding an animal weighing between about 400 Kg and about 1,200 Kg.

In one embodiment, the present invention provides for a method ofinstalling cushioning device at a site. In one embodiment, theinstallation method includes: (a) providing a cushioning device having adrop stitch structure and a chamber configured for receiving a fillingmaterial, (b) delivering the cushioning device and an amount of apolymer capable of producing gel upon contact with a liquid to the site,and (c) mixing the polymer with a controlled mixture of the liquid tocreate the gel inside the chamber of the cushioning device.

In one embodiment of the method, the cushioning device is delivered withthe amount of polymer inside the chamber or outside the chamber.

In another embodiment of the method, the method further comprisesintroducing a gas into the chamber.

In one embodiment, the present invention provides for a kit comprising(a) a cushioning device of any of the above embodiments and (b) afilling material.

In one embodiment of the kit, the filling material is provided insidethe chamber.

In another embodiment of the kit, the filling material is providedoutside the chamber.

In yet another embodiment of the kit, the kit further comprises aninstallation manual.

In one embodiment of the kits of the present invention, the cushioningdevice is a large animal cushioning device.

In one embodiment of the kit of the present invention, the large animalincludes a cow, a horse, a buffalo a goat and a pig.

In one embodiment of the kits of the present invention, the cushioningdevice when filled with the filling material is capable of withstandingan animal weighing more than about 400 Kg.

In another embodiment of the kits of the present invention, thecushioning device when filled with the filling material is capable ofwithstanding an animal weighing between about 400 Kg and about 1,200 Kg.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an isometric view of a cushioning device inaccordance to one embodiment of the present invention.

FIG. 2A illustrates a top view of a cushioning device in accordance toone embodiment of the present invention. FIG. 2B is a cross section viewof the cushioning device of FIG. 2A through A-A. FIG. 2C is a detailedview of FIG. 2B illustrating different layers in accordance with oneembodiment of the present invention.

FIG. 3A illustrates a cross section of a cushioning device in accordanceto one embodiment of the present invention showing a drop stitchstructure.

FIG. 3B illustrates a cross section of a cushioning device in accordanceto one embodiment of the present invention showing a drop stitchstructure.

FIG. 4 is a perspective view of a cushioning device for large animals inaccordance to one embodiment of the present invention illustrating acushioning device installed.

FIG. 5A is a perspective view of a system of cushioning devices forlarge animals in accordance to another embodiment of the presentinvention.

FIG. 5B is a detail view of the area indicated by dashed rectangle “a”of FIG. 5A.

FIG. 6 is a perspective view illustrating the layers of a wall of acushioning device for large animals in accordance with one embodiment ofthe present invention.

FIG. 7 is an isometric top view of one corner of an inflatable mattress,showing one valve cap with septum in accordance to one embodiment of thepresent invention shown above the filling port on the inflatablemattress.

FIG. 8 is an isometric top view of one corner of an inflatable mattress,showing one valve cap with septum in accordance to one embodiment of thepresent invention installed on the inflatable mattress

FIG. 9 is an isometric top view of an inflatable mattress including twovalve caps with septa in accordance to one embodiment of the presentinvention.

FIG. 10 is an isometric exploded perspective view from the top of avalve cap with septum in accordance to one embodiment of the presentinvention.

FIG. 11 is an isometric exploded perspective view from the bottom of avalve cap with septum in accordance to one embodiment of the presentinvention.

FIG. 12 is an isometric perspective view from the bottom of a valve capand a grommet with septum in accordance with one embodiment of thepresent invention.

FIG. 13 is an isometric top view of one corner of an inflatable mattressshowing one valve cap with septum installed on the inflatable mattress,with a syringe of filling fluid shown in position ready to be insertedinto the valve cap with septum in accordance to one embodiment of thepresent invention.

FIG. 14 is an isometric top view of one corner of an inflatable mattressshowing a valve cap with septum installed on the inflatable mattress,with a syringe of filing fluid shown inserted through the septum of thevalve cap in accordance to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Also, unless indicatedotherwise, except within the claims, the use of “or” includes “and” andvice-versa. Non-limiting terms are not to be construed as limitingunless expressly stated or the context clearly indicates otherwise (forexample “including”, “having” and “comprising” typically indicate“including without limitation”). Singular forms including in the claimssuch as “a”, “an” and “the” include the plural reference unlessexpressly stated otherwise. All publications cited herein, as well asthe priority document, are incorporated by reference in their entirety.

“Inflatable”, as used in this document, means inflation with a suitablefilling material. The filling material includes any suitable fluid orcombination of fluids. Suitable fluids include gaseous compounds and/orliquids, including gels.

“Large animals” refer to livestock species such as cattle, buffalos,horses, sheep, goats, and pigs. The term “large animal” excludes pets,such as dogs and cats regardless of their size and weight.

The invention will be explained in details by referring to the figures.

The Cushioning Device

The present invention relates to a cushioning device that may be filledwith a gaseous compound or a mixture of gaseous compound and a liquid.In one embodiment, the cushioning device of the present inventionincludes a drop stitch structure and a chamber configured for receivingan amount of the filling material capable of withstanding a largeanimal. As such, the present invention relates also to a large animalcushioning device.

The cushioning device of the present invention may take an overallconfiguration which may be the same, or has similarities to, a mattress.As such, the cushioning device of the present invention may also bereferred to in this document as a mattress. With reference to FIG. 1,reference numeral 100 denotes generally a cushioning device, which maycomprise of an inflatable bladder capable of withstanding a largeanimal, such as cow or buffalo. A cow/bull may weigh between about 900pounds and about 3,000 pounds. A buffalo may weigh between about 2100pounds and about 2600 pounds. Accordingly, the cushioning device of thepresent invention may be capable of withstanding animals having a weightbetween about 900 pounds and about 2,600 pounds (between about 400 Kg toabout 1,200 Kg). The cushioning device 100 of the present invention maycomprise a top or first wall 120, and a bottom or second wall 130. Thetop and bottom walls 120, 130 may form a chamber. The chamber may beconfigured to receive a filling material for filling the chamber of thecushioning device 100. The cushioning device may also includefilling/retrieving means such as a port 110 for disposing or retrievinga filling material into/from the chamber.

To form the chamber, the top and bottom walls 120, 130 may be connectedat their peripheral ends throughout the periphery of the cushioningdevice 100 to form a peripheral structure. It may be necessary to sealthe chamber to prevent the filling material from leaking out of thecushioning device. In this case, the top and bottom surfaces 120, 130may be connected directly at their peripheral end by sealed end seams inorder to create the sealed chamber (see in FIG. 7 end seams 701).Alternatively, the top and bottom surfaces may be connected at theirperipheral ends to side walls 140, for example by sealed end seams.

Along the periphery of the cushioning device, additional layers may beused to couple the top and bottom surfaces. This configuration is shownin FIG. 2 for clarity. FIG. 2 illustrates a cushioning device 200 havinga top wall 220 and a bottom wall 230 and a periphery or side wall 201.Also shown is a port 210. FIG. 2C details a cross section of thecushioning device 200 (for convenience only, FIG. 2C does not illustratethe drop stitch structure, which is illustrated in FIG. 3A and FIG. 3B).Item 201 designates a periphery having a layer which may be comprised ofpolyvinylchloride (PVC) which may include a scrim, which may be a nylonscrim. Items 220 and 230 designate the top and bottom walls of amattress 200. The top and bottom walls 220, 230 may include an outerlayer, which may be made of PVC, with scrim. Item 242 designates aportion of the periphery in which the scrim PVC 201 overlaps with thetop or bottom surfaces 220, 230 forming the peripheral structure 242.The peripheral structure 242 may be provided with an additional layer202, which may be made of a PVC without a scrim. Item 202 may serve toprovide an additional liquid tight seal where Items 201 and 230 may bebound together. Item 202 may also serve to provide an additional meansof transmitting the shear forces experienced in the joint between items201 and 230.

The basic structure of the cushioning device of the present inventionincludes a drop stitch structure. FIG. 3A illustrates, in oneembodiment, the top wall 320 and the bottom wall 330 interconnected byfabric stitching 370 to form a drop stitch structure 350 of thecushioning device of the present invention.

As shown in FIG. 3A, the “drop stitch fabric” generally shown as 350includes two opposing base layers 352 and 354, with a core section 356positioned between (and connected to) the base layers 352 and 354. Thiscore section 356 may include a plurality of individual threads or cords370 which have upper and lower end portions which connect to,respectively, the upper and lower layers 352 and 354. Threads 370 may bemade of any suitable material, such as nylon.

Each of the top wall and the bottom wall of the cushioning device of thepresent invention may be made of one layer or of at least one layer. Assuch the bottom and top walls may be made of 1, 2, 3, 4, 5 or morelayers. FIG. 3A illustrates a top wall 320 and a bottom wall 330including four layers each. With reference to FIG. 3A, the layers of thewalls will now be described in order from the chamber 310 to theexterior surface of the cushioning device 300. In the embodiment shownin FIG. 3, the top and bottom walls 320, 330 may include two opposingbase layers 352, 354 lining or covering the chamber 310. The opposingbase layers 352, 354 may be connected by a drop stitch structure 350.The base layers 352, 354 may be a cloth or fabric made of nylon,ballistic nylon or similar materials, and they may serve to providestrength and durability to the cushioning device, as well as enableshape retention. The base layers 352, 354 may in turn be lined by ascrim layer, as shown in FIG. 3. The scrim layer may include two sheetlayers having a scrim sheet in between. The scrim layer may, forexample, be made of PVC sheets 383 a,b, 385 a,b having a nylon scrim387, 389. The scrim layer may serve to provide a fluid tight seal,durability and resistance to degradation in harsh environments such asanimal urine or feces. The base cloth 352, 354, and scrim layer may belaminated together.

FIG. 3B shows another embodiment of a cushioning device having adrop-stitch structure. In this embodiment, the top and bottom wallsinclude five layers each 82, 83, 84, 85, 86. Layers 82 may be basedlayers joined by a plurality of individual threads or cords 87.

FIG. 6 illustrates the different layers forming a wall of the cushioningdevice of the present invention: the base layer 610 that covers or linethe chamber of the cushioning device and forms part of the drop-stitchstructure, and the scrim layer 620. The base fabric layer 610 may be apolypropylene fabric layer. The scrim layer 620 may include two PVCsheets 622, 626 and a scrim sheet 624, which may be made of, but notlimited to, nylon, ballistic nylon, nylon 6, polyester, or similarfabric like materials in between the two PVC sheets 622, 626.

As illustrated in FIG. 4, the cushioning device 400 of the presentinvention may be placed over a deck 410, such as a concrete deck. Aprotective, abrasion resistant sheet 412 may be used to line the deck410, and adjacent to the bottom surface of the mattress 400. Protectivesheet 412 may be a suitable polypropylene fabric. An abrasion resistantcover sheet 414 may be used adjacent to the top surface of thecushioning device 400. The abrasion resistant cover sheet 414 may bemade of polypropylene or a suitable rubber material. One or morecoupling means 417, 419 may be used to maintain the cushioning device400 substantially immobilized on the deck. Item 419 may take the form ofa plastic arch/barrier. Item 417 may take the form of a plastic strip.

The cushioning device of the present invention may be inflated utilizinga filling station in fluid communication with one or more ports on thecushioning device enabling the introduction of the filling materialin/from the chamber. In one embodiment, the filling station may disposea liquid, a gaseous compound or a mixture of the aforementioned fillingmaterials into the chamber of the cushioning device. Subsequent to thecushioning device being sufficiently inflated it may be manuallydisposed on the deck. According to another embodiment of the invention,the cushioning device may subsequently be covered with a protectivesheet 414. One or more coupling means, 417, 419 may be used to maintainthe protective sheet and cushioning device substantially immobilized onthe deck 410.

The cushioning device of the present invention may include one or moremeans for disposing and retrieving the filling material in/from thechamber. In one embodiment, a standard port may be provided on thecushioning device to permit entry and exit of the filling materialto/from the chamber (see for example item 110 of FIG. 1). In oneembodiment, the port may be comprised of an inlet or intake port and anoutlet or exhaust port. A single port may be used to enable theinflation and/or installation of the cushioning device of the presentinvention with the filling materials. FIG. 5A illustrates an exhaustvalve 510 and an intake valve 512 which may be included in each mattress501, 502. In one embodiment, the one or more ports for disposing andretrieving the filling material may be in fluid communication with apowered or non-powered reservoir including but not limited to apressurized fluid reservoir, gas compressor or fluid pump. Thecushioning device may be inflated by providing a means of fluidcommunication to the aforementioned reservoir through the implementationof a fluid conduit. FIG. 5A illustrates a fluid conduit, trunk line 514which may communicate a fluid reservoir with a plurality of cushioningdevices.

FIG. 5B illustrates detail of dashed rectangle a, in which the exhaustport check valve 510, the inlet port check valve 512, the trunk line 514to reservoir, and drop stitch mattress 501. Item 515 illustrates aspacer wedge.

The Filling Material

In the present invention the filling materials may include one fluid, ora mixture of fluids having different viscosities or being in differentphysical states. As such, in one embodiment, the filling material mayinclude or consist of a gaseous compound, including a mixture of gases.In other embodiments the filling material may be a mixture of a gaseouscompound such as air, and substances in liquid state, such as water andgelatinous materials.

The gaseous compound may be an inert gas. Examples of gases that may beused to fill the cushioning device of the present invention include air,nitrogen and argon. Other gases may also be used.

The liquid may include a gelatinous filling material. The gelatinousmaterial may be provided as a compound, preferably substantially dry orpowder form that creates a gel when in contact with a liquid solutionsuch as water. Examples of such a compound for creating the gelatinousmaterial may include a polymer such as a superabsorbent polymer (SAP).SAP is commonly used in the hygiene industry, particularly in themanufacture of diapers to absorb body fluids. As such, a preferredmaterial for providing a gelatinous filling material may be in the formof a powder or granules made up of SAP, and the powder or granules maybe interspersed throughout the chamber. An example may be the sodiumpolyacrylate AP95 OS produced by Evonik Stockhousenr®.

When SAP is in contact with a liquid, such as water, it creates a gelthat can last as a gelatinous material for many years when inside asealed chamber.

SAP that may be used in the present invention include absorbent polymersthat absorb liquids and are commonly used in the manufacture of sanitaryarticles. SAP that may be used in the present invention include polymersthat absorb over 50 times, more preferably over 75 times, even morepreferably over 100 times, its weight in water. Non-limiting examples ofSAP that may be used according to the present invention include sodiumpolyacrylate, sodium polyacrylamide, and potassium polyacrylamide.

The high viscosity of the gelatinous filling material that may beincluded within the chamber of the cushioning device may create impactabsorption to absorb energy peaks. Also, the conformability of the gelmay help reduce the pressure points on joints or extremities of thelarge animal, which may result, in the case of cows, in an increase inthe milk production.

If a mixture of gas and gelatinous material are used to fill thechamber, the cushioning device may include about 1-20% v/v % gas and80-99% v/v % gelatinous material, and any possible range of gas togelatinous material therein between.

System

In another embodiment, the present invention relates to a system forproviding comfort to large animals. The system may include (a) at leastone cushioning device of the present invention, and (b) a source offilling material in connection with the at least one cushioning device.

The system, in another embodiment, may include: (a) one or morecushioning devices, each cushioning device including a chamberconfigured for receiving a filling material, and (b) a source of fillingmaterial in connection with the one or more of cushioning devices. Inone aspect, the one or more cushioning device may include a drop stitchstructure. In another embodiment, the cushioning device is a largeanimal cushioning device.

The one or more cushioning devices may be interconnected to one or morereservoirs of filling material that enables the adjusting or maintainingpressure once the mattresses are installed; the adjustment may be basedon animal attributes (health, weight) or compensating for thestretching/aging of the mattress. The system may include a trunk lineconnecting the one or more cushioning devices to a source of fillingmaterial, such as a gas reservoir. The mattresses and connections in thesystem may be maintained at a desired pressure. If a mattress in thesystem falls below the pressure at which the system is set, then,because of pressure differential, the system automatically (i.e. withoutthe input of an operator) fills the mattress, thereby bringing thepressure back to the system's pressure.

In one particular embodiment, the system may include a plurality ofcushioning devices of the present invention and the source of fillingmaterial.

Shown in FIG. 5A and in FIG. 5B is a system 500 of a plurality ofdrop-stitch, large animal cushioning devices of the present invention501, 502. The cushioning devices 501, 502 may be placed on top of a deck505 lined with a protective layer 506, which may be made of PVC. Thecushioning devices 501, 502 may be covered by a cover 504 which may bemade of PVC or a suitable rubber material. For illustration purposesonly, a portion of the rubber cover 504 is cut-out to show cushioningdevices 501, 502, but it should be understood that the system mayinclude 2, 3, 4 or more cushioning devices.

The cushioning devices 501, 502 may include intake valves 512, andexhaust valves 510. Each intake valve 512 includes an intake check valveconfigured for allowing filling fluid to flow into the cushioning device501, 502, while preventing the fluid from flowing out of the cushioningdevice 501, 502. Each exhaust valve 510 includes an exhaust check valveconfigured for allowing filling fluid to flow out of the cushioningdevice 501, 502, while preventing fluid from flowing back into thecushioning device 501, 502. Each exhaust valve may be connected to anexhaust conduit included in a trunk line 514. Each intake valve 512 maybe preferably connected to an intake conduit included in the trunk line514.

Through extension of the trunk line 514 each intake valve 512 is incommunication, such as fluid communication, with a powered ornon-powered fluid reservoir including but not limited to a pressurizedfluid reservoir, gas compressor or fluid pump (not shown). The exhaustvalve through extension of the trunk line 514 may be in fluidcommunication with a pressurized fluid reservoir, or atmosphere throughthe implementation of a pressure regulator (not shown). Generally, thefluid included in the supply and exhaust reservoir is a gaseouscompound, however, a liquid such as water, or a mixture of gas andliquid may also be suitable.

The weight of a body such as a cow resting, or standing, or the impactof a cow in transition from the resting to standing position and viceversa may deform the chamber of a cushioning device. Thus the pressureof the fluid within each chamber increases as the volume of the chamberdecreases under deformation. As the pressure of the fluid increases, thefluid in the affected cushioning device(s) flows out of the chamberthrough a corresponding exhaust valve and into the pressure regulatedtrunk line and reservoir. The aforementioned sequence of events occurssuch that the entire system remains substantially close to or atequilibrium, thereby maintaining the desired level of comfort throughoutthe entire spectrum of events imposed by animal occupancy.

Valve Cap with Septum

The present invention, in another embodiment, additionally providesmeans for the re-pressurization of an inflatable bladder such as thecushioning device of the present invention subsequent to installation ofthe inflatable mattress. In one embodiment, the re-pressurization may beachieved through the incorporation of a septum or check valve orequivalent within the valve cap that facilitates fluid communicationwith regions exterior to the chamber of the inflatable bladder.

The present invention also provides for a cap with septum for use in aninflatable bladder such as gas, liquid or both liquid and gas filledmattresses where it may be desired to re-pressurize the bladder byadding relatively small amounts of fluid, such as gas, liquid or amixture of gas and liquid. In one embodiment of the present inventionthere is provided a cap for sealing a filling port of an inflatablebladder having a chamber, the cap comprising (i) a main body, (ii) aconnector extending from the main body, the connector designed forinterfacing with the filling port of the inflatable bladder, and (iii) aseptum disposed in the cap such that an inflation member, such as aneedle, can be inserted through the septum and into the chamber of thecushioning device.

With reference to FIGS. 7 to 11, the cap 10 of the present invention mayinclude a main body 12 with a top wall 14 and a bottom wall 16. Bottomwall 16 may include a gasket 13 for better sealing the filling port.Extending from the bottom wall 16 there is a connector or throat 18configured for engagement to or interfacing with a filling port 2 of aninflatable bladder 1 and having a free bottom wall 19. The connector 18may include external threads 17 that may match threads 3 in the fillingport. Alternative to the threads, the connector may include one or moreribs or rings made of a flexible material like rubber, for frictionallyengaging the filling port. The cap 10 includes a channel 20, which maybe centrally located, that extends from an opening 22 on the top wall 14through the main body 12, through connector 18, and ending in anaperture 24 on the bottom wall 19 of the throat 18. The two opposingopenings 22, 24 may be arranged substantially co-axially on axiallyopposite ends of the channel 20. Opening 24 may be smaller in diameter,including slightly smaller, than opening 22. The side walls 25 ofchannel 20 may be threaded.

The septum 30 may be configured for essentially fitting inside channel20. Within the channel 20, septum 30 may sit on the inside surface ofthroat's 18 bottom wall 19 thereby covering opening 24. The septum maybe frictionally engaging the side walls of the throat. Septa may be madefrom silicone, rubber, or other similar materials. The trait that thesematerials have is that when a needle is pushed through them, the septumseals around the needle during insertion, and then when removed, theneedle hole closes back up and seals again.

A plugging device, such as a plug 40, may be used to retain the septum30 in place within cavity 20 and covering opening 24. Plug 40 mayinclude a top wall 42, a bottom wall 44 and side walls 46. Side walls 46may include threads 47 matching the threads of the side walls 25 ofthroat 18. Instead of threads, side walls of the plug may include one ormore ribs or rings that would frictionally engage with the side walls ofthe cap's cavity. Plug 40 may include a hole 45, which may be centrallylocated, having two openings 41, 43 that may be arranged substantiallyco-axially on the axially opposite top and bottom walls 42, 44 of theplug 40 respectively. Opening 41 may be designed to receive the head ofbit of a screwdriver or other devices such as a hex key.

Referring to FIG. 12, another embodiment of the cap with septum ofpresent invention is illustrated. When referring elements of the cap,the same reference numbers of FIGS. 7-11 will be used for convenience.In this embodiment, the septum 62 may be provided in a grommet 61 thatmay be inserted into the aperture 24 located on the bottom wall 19 ofconnector 18 of the cap 10. Grommet 61 may include an external flange 66and an internal flange 68. The external flange 66 and the internalflange 68 define a groove 69 there in between. The internal flange 68may include a surface 65 designed for easier insertion of the grommetthrough the aperture 24. For example, surface 65 may be tapered. Wheninserted, the internal flange 68 becomes disposed in the interior ofchannel 20 of cap 10, while the external flange may remain adjacent tothe bottom wall 19 of the cap 10. The groove 69 is adapted to receive alip 64 of the aperture 24 disposed on the bottom wall 19 and mayestablish a seal between the grommet and the lip of the aperture 24. Thegroove 69 and flanges 66, 68 may have a contour which is complementaryto the shape of the aperture 24. That is, the shape of grommet 61 may bedesigned to fit any specific aperture opening or shape such as circular,square, rectangular, etc. by changing the contours of the internal andexternal flanges. An improvement of the grommet of the present inventionis that it includes a septum 62. Septum 62 may be disposed within theexternal flange 66. The grommet of the present invention may be made ofany suitable material, preferably from a resilient or elastomericmaterial such as polyurethane.

With reference to FIGS. 13 and 14, hole 45 may be designed to allow aneedle 52 go through it and be inserted through the septum and into thefilling port 2 of the inflatable bladder 1.

The inflation needle should be a non-coring needle. This means that theneedle can spread open the septum, but will not puncture a hole in it.The inflation needle may be connected to a source of filling material.FIGS. 13 and 14 illustrate an inflation needle 52 connected to a syringe50 having a filling material. The inflation needle may alternatively beconnected directly to a hose or pump to push the filling material intothe inflatable bladder.

In assembling the cap of the present invention, the septum may bepositioned within the channel of the cap, preferably sitting on thebottom wall of the cap's connector and covering the connector's bottomwall's opening. When a plug is used to retain the septum in place, theseptum may be inserted through the opening on the top wall of the mainbody first and then the plug is inserted in the cavity, for examplemanually or using a screw driver, a hex key or any other suitabledevice, to keep the septum in place.

The cap of the present invention may be used to seal an inflatablebladder such as an inflatable mattress, by connecting the connector orthroat of the cap into a filling port of the inflatable mattress. Withreference to FIGS. 13 and 14 if the mattress needs more internalpressure, in operation, a suitable needle 52 connected to a syringe 50or to other device containing a filling material, may be inserted intothe plug's 40 hole 45, through the septum within the cavity and into thefilling port 2 of the inflatable bladder 1. The filling material maythen be pushed into the inflatable bladder 1, as illustrated in FIG. 14,until a desired internal pressure is attained. The needle 52 may then beretrieved from the plug's 40 hole 45.

The cap of the present invention may be used for filling relativelysmall amount of filling fluids or gas into an inflatable bladder, suchas the cushioning device of the present invention, through the septumwith a suitable member such as a needle. The advantage is that it willbe much simpler and faster to add relatively small amounts of fillingmaterial to the inflatable bladder if the inflatable bladder were tobecome soft, for example, because of the material stretching, which mayoften occur in the case of inflatable mattresses for large animals dueto the weight of the large animals.

The cap with septum of the present invention provides an easy way to addfluid or gas the cushioning device of the present invention or to anyother inflatable bladder. Adding filling fluid or air through the septumallows to leave the inflatable bladder closed, which saves time.

Delivery and Installation of the Cushioning Device

In one embodiment, the present invention provides for a kit comprising(a) a cushioning device according to one embodiment of the presentinvention and (b) a compound capable of creating a gelatinous fillingmaterial when in contact with a liquid solution such as water. The kitmay also comprise instructions on how to install and/or care for thecushioning device. The kit may also comprise a cover for covering saidcushioning device. The kit may also comprise a layer of protection forunder the said cushioning device. The kit may also include a fluidreservoir and/or trunk line mentioned above.

In another embodiment, the present invention also provides for methodsof transporting, delivering, distributing or shipping a cushioningdevice of the present invention to a site, such as a stall in a farm ora distributor of the cushioning device. These methods may beparticularly useful to keep the shipping volumes and weights to aminimum. When the filling material includes a mixture of gelatinouscompound and gas, one such method of transporting a cushioning device toa site may comprise delivering to the site the cushioning device with anamount of a compound capable of creating the gelatinous material when incontact with a liquid already disposed within the chamber. The amount ofcompound to be used would depend at least on the compound being used,and the dimensions of the chamber. For example, the dimensions maycreate a chamber that can hold approximately 100 litres of water, and acertain SAP can absorb a ratio of 1:100 by weight. In this case, theamount of SAP needed may be about 1 kg. The cushioning device with thecompound disposed in the chamber may, for example, be packaged in acontainer for transportation to the site. At the installation site anamount of the liquid may be introduced into the chamber thereby creatingthe gel within the chamber and, when a mixture is used, an amount of agas and installing the cushioning device at the site.

Alternatively, the cushioning device and an amount of the compoundcapable of creating the gelatinous material upon contact with a liquidmay be delivered separately to the site (i.e. the compound is notdisposed within the chamber). The cushioning device and the amount ofcompound may, for example, be packaged in a container for transportationto the site. The compound may be provided, for example, in a plasticbag. The amount of compound to be delivered may depend, as providedbefore, at least on the compound being used and the dimensions of thechamber. At the remote site the compound may be disposed within thechamber and the chamber may then be filled with an amount of liquid tocreate the gelatinous filling material within the cushioning device. Agaseous compound may also be introduced within the chamber.

When filling the cushioning device, a balance between the comfort of thelarge animal such as a cow or a horse, and the clean-ability of thesurface of the cushioning device may be maintained. Clean-abilityaffects the work input for the farmer and the hygiene for the cow. Bothcomfort and hygiene can affect the milk production levels of a cow.

The inventors discovered that a preferable balance between comfort andclean-ability may be achieved when the chamber of the cushioning devicehas a positive pressure, that is a positively past the atmosphericpressure. This pressure within the chamber may range from about 0.1 psito about 12 psi when there is no large animal on the cushioning device.This positive pressure may ensure that, for example, when there is not acow on the cushioning device, the cushioning device of the invention mayremain in the fully inflated form without any indentations or low spotsin the walls. When there are no indentations or low spots, the mattressmay be easier to clean and the liquid matter may drain properly.However, within this range of positive pressure, since the large animalsare heavy, they may still be capable of indenting the mattress, which iscritical for animal comfort.

Depending on the material being used to manufacture the cushioningdevice, such as a mattress, there may be some elastic and some permanentstretch in the material. In a preferred configuration, reinforced PVCmay be used with internal glue and threads for the construction. Thisleads to a mattress having a relatively small amount of permanentstretch after it is first used. Thus, in order to maintain the positivepressure (as described above), the mattress may need an extra preloadduring installation. The preload may vary depending on the material ofthe mattress, but for the preferred configuration, the preload may beabout 2 psi. Thus the installation pressure in the cushioning device maybe between about 2.1 psi and about 14 psi. It is expected that thispreload installation pressure may drop to a desired final pressureduring the first month of use of the cushioning device.

To achieve the right pressure within the cushioning device of thepresent invention, an installer may use a manual valve with a pressuregauge to achieve the right pressure. Gas may be included to achieve thedesired pressure. The pressure may also be automatically regulated usingthe manifold system previously described.

Advantages

Advantages of independent (i.e. not in fluid communication) cushioningdevices (gas only or hybrid gas/gel) of the present invention include:inclusion of gas, such as air, further aids in impact absorption whenanimal gets up and down in comparison to existing cushioning device ormattress systems; simplified installation procedure as compared tosimilar mattresses or cushioning devices; adds to the longevity of themattress; compensates for stretching of PVC; added compensation fortemperature fluctuations; drop-stitch structure makes mattresscushioning devices of the present invention substantially or completelyflat which helps keep it clean; i.e. more hygienic for the animal; lowtransportation costs, because fluid may be added at installation site.

Advantages of cushioning devices with manifold system—could be just gasor Hybrid (gel/gas), include: improved impact absorption which maybenefit health of the animal; variable pressure settings for comfortcustomization depending on animal attributes (weight, health); uniformpressure throughout all cushioning devices in the system, which are influid communication; continued comfort compensation as the cushioningdevice ages and stretches; drop-stitch structure makes mattress orcushioning device substantially or completely flat which helps keep itclean; i.e. more hygienic for the animal, and less labour intensive toclean; lightweight at installation (air), good ergonomics forinstallation technicians; enables compensation for temperaturevariations within filling fluid; mat size can be for 1 or more animalse.g. 1 to 5 or more animals; decreasing amount failure areas; andfurther simplifying installation.

Other unique attributes of the cushioning devices and systems of thepresent invention include: drop stitch has never been used in mattresssystem, including mattresses for large animals; provides uniquesubstantially or completely flat surface for animal; uses a combinationof fluids and gases to achieve cushioning effect; the device may remainin fluid communication with exterior regions, such as an air reservoirthrough at least one inlet and maybe one exhaust line; polypropylenefabric layers for extra protection against abrasion during usage.

The above disclosure generally describes the present invention. Changesin form and substitution of equivalents are contemplated ascircumstances may suggest or render expedient. Although specific termshave been employed herein, such terms are intended in a descriptivesense and not for purposes of limitation. It is to be understood thatthe present invention is not limited to the embodiments described above,but encompasses any and all embodiments within the scope of thefollowing claims.

1-40. (canceled)
 41. A large animal cushioning device, the large animalcushioning device comprising: a drop stitch structure, a chamber filledwith an amount of a filling material that exerts an installationpressure inside the chamber, the filling material being a mixture of agaseous compound and a liquid, and a gas supply reservoir in fluidconnection with the chamber of the cushioning device that supplies thegaseous compound to the chamber, the gas supply reservoir configured formaintaining the installation pressure inside the chamber.
 42. Thecushioning device of claim 41, wherein the cushioning device furthercomprises: (a) a top wall that is a generally flat surface and (b) abottom wall, the top and bottom surfaces being connected by the dropstitch structure, the top and bottom walls forming the chamber, whereinthe amount of filling material exerts the installation pressure againstthe top and bottom walls such that before use by the large animal thetop wall stretches up to 10% of its original size, the cushioning devicehaving the installation pressure inside the chamber, the installationpressure being from about 2.1 PSI to about 14 PSI such that after use bythe large animal the top wall returns to its generally flat surface. 43.The cushioning device of claim 41, wherein the liquid is water.
 44. Thecushioning device of claim 41, wherein the gaseous compound includesair, nitrogen, argon, or a combination thereof.
 45. The cushioningdevice of claim 42, wherein the drop-stitch structure comprises twoopposing base layers connected by a plurality of threads, and whereinthe two opposing layers directly line the chamber of the cushioningdevice.
 46. The cushioning device of claim 45, wherein each of the topand bottom walls includes (i) a base fabric layer directly lining thechamber, the base fabric layer of the top wall being connected to thebase fabric layer of the bottom wall by the drop stitch structure and(ii) a fluid tight scrim layer lining the base layer, the scrim layercomprising two sheet layers having a scrim sheet in between.
 47. Thecushioning device of claim 41, wherein the cushioning device furtherincludes an intake valve, the intake valve being connected with the gassupply reservoir, the intake valve having an intake check valveconfigured for allowing the gas of the gas supply reservoir to flow intothe cushioning device, while preventing the filling material fromflowing out of the cushioning device.
 48. The cushioning device of claim41, wherein the cushioning device when filled with the filling materialis capable of withstanding an animal weighing more than about 400 Kg.49. A kit comprising (a) a cushioning device of claim 41 and (b) afilling material.
 50. The kit of claim 49, wherein the filling materialis provided inside the chamber or outside the chamber.
 51. The kit ofclaim 49, wherein the kit further comprises an installation manual.